Layered cord for tire belt

ABSTRACT

A compact metal cable having two layers (C 1 , C 2 ) of construction 1+N, rubberized in situ, usable in particular as a reinforcing element for a tire belt for a heavy industrial vehicle, comprising a core or inner layer (C 1 ) comprising a single core wire of diameter d 1 , and a saturated outer layer (C 2 ) of N wires of diameter d 2  wound together in a helix at a pitch p 2  around the layer C 1 , said layered cable being characterized:
         in that it has the following characteristics (d 1 , d 2 , p 2  in mm):
           0.15&lt;d 1 &lt;0.50;   0.15&lt;d 2 &lt;0.50;   8&lt;p 2 &lt;25;   
           and in that the core wire is surrounded by a sheath of diene rubber which fills, at least in part, the gaps between the core wire and the cords of the layer C 2.

The present invention relates to two-layer metal cables, of constructionl+N, usable in particular for reinforcing rubber articles.

It also relates to tires and to the reinforcement armatures of thecrown, also referred to as “belts”, of these tires, in particular to thereinforcement of the belts of tires for heavy industrial vehicles.

A tire having a radial carcass reinforcement in known manner comprises atread, two inextensible beads, two sidewalls joining the beads to thetread and a belt arranged circumferentially between the carcassreinforcement and the tread, this belt being formed of various plies (or“layers”) of rubber which may or may not be reinforced by reinforcementelements (“reinforcing threads”) such as cables or monofilaments, of themetallic or textile type.

The tire belt is generally formed of at least two superposed belt plies,sometimes referred to as “working” plies or “crossed” plies, thegenerally metallic reinforcement cables of which are arranged inpractice parallel to one another within a ply, but crossed from one plyto the other, that is to say inclined, whether symmetrically or not,relative to the median circumferential plane, by an angle which isgenerally of between 10° and 45° depending on the type of tire inquestion. The crossed plies may be finished off by various other pliesor auxiliary layers of rubber, of widths which are variable depending onthe case, and which may or may not comprise reinforcing threads; mentionwill be made by way of example of simple cushions of rubber, what arecalled “protective” plies, the role of which is to protect the rest ofthe belt from external attack and perforations, or alternatively whatare called “hooping” plies comprising reinforcing threads orientedsubstantially in the circumferential direction (what are called“zero-degree” plies), be they radially external or internal relative tothe crossed plies.

A tire belt must in known manner fulfil various demands, which arefrequently contradictory, in particular:

-   -   be as rigid as possible at low deformation, because it        contributes substantially to stiffening the crown of the tire;    -   have a hysteresis which is as low as possible, in order on one        hand to minimise the heating during travel of the inner zone of        the crown and on the other hand to reduce the rolling resistance        of the tire, which is synonymous with saving fuel;    -   finally have high endurance, with respect in particular to the        phenomenon of separation, cracking of the ends of the crossed        plies in the shoulder zone of the tire, known by the name        “cleavage”, which requires in particular the metal cables which        reinforce the belt plies to have high fatigue strength in        compression, all in a more or less corrosive atmosphere.

The third demand is particularly strong for heavy-vehicle tires,designed to be able to be retreaded one or more times when the treadswhich they comprise reach a critical degree of wear after prolongedtravel.

For the reinforcement of the belts above, generally steel cables (“steelcords”) referred to as “layered” (“layered cords”), formed of a centralcore and one or more concentric layers of wires arranged around thiscore, are used. The layered cables most used are essentially cables ofconstruction M+N or M+N+P, formed in known manner of a core of M wire(s)surrounded by at least one layer of N wires, possibly itself surroundedby an outer layer of P wires.

The availability of carbon steels which are becoming ever stronger andmore enduring, in particular, means that tire manufacturers nowadays, asmuch as possible, are tending towards the use of cables having only twolayers, in order in particular to simplify the manufacture of thesecables, reduce the thickness of the composite reinforcement plies, andultimately reduce the costs of the tires themselves.

The two-layer cables essentially used hitherto in the belts of tires areessentially cables of construction 2+7, 3+8 and 3+9, formed of a core orcentre of 2 or 3 wires and an outer layer of N wires (respectively 7, 8or 9 wires) which is more or less unsaturated owing to the largediameter of the core produced by the presence of the two or three corewires.

It is known that this type of construction promotes the ability of thecable to be penetrated from the outside by the calendering rubber of thetire or of the rubber article during the curing of the latter, andconsequently makes it possible to improve the endurance of the layeredcables in terms of fatigue and fatigue-corrosion, particularly withrespect to the problem of cleavage mentioned previously.

These 2+7, 3+8 and 3+9 cables are however not without drawbacks.

Cables of construction 3+8 and 3+9 cannot be penetrated as far as thecore owing to the presence of a channel or capillary at the centre ofthe three core wires, which remains empty after impregnation by therubber, and therefore favourable to the propagation of corrosive mediasuch as water. As for 2+7 cables, as furthermore with the previous ones,they are still relatively bulky with a low strength per unit of sectionowing to their unsaturated outer layer.

Furthermore, one major objective of a tire manufacturer wishing toreduce the hysteresis of the belts of tires is nowadays to reduce thethickness of the composite reinforcement fabrics used in these belts, inparticular owing to the use of highly compact cables.

In continuing their research, the Applicants have discovered a novellayered cable, of construction 1+N, rubberized in situ, which not onlyhas increased resistance to corrosion, but also and above all impartsimproved endurance in compression to the belts of the tires. Thelongevity of the tires and that of their crown reinforcements is thussignificantly improved, very particularly with regard to the phenomenonof cleavage previously explained.

Consequently, a first subject of the invention is a compact metal cablehaving two layers (C1, C2) of construction 1+N, usable in particular asa reinforcing element for a tire belt for a heavy industrial vehicle,comprising a core or inner layer (C1) comprising a single core wire ofdiameter d₁, and a saturated outer layer (C2) of N wires of diameter d₂wound together in a helix at a pitch p₂ around the layer C1, saidlayered cable being characterized:

-   -   in that it has the following characteristics (d₁, d₂, p₂ in mm):        -   0.15<d₁<0.50;        -   0.15<d₂<0.50;        -   8<p₂<25;    -   and in that the core wire is surrounded by a sheath of diene        rubber which fills, at least in part, the gaps between the core        wire and the wires of the layer C2.

The invention also relates to the use of a cable according to theinvention for reinforcing articles or semi-finished products made ofrubber, for example plies, tubes, belts, conveyor belts and tires.

The cable of the invention is very particularly intended to be used as areinforcing element for a belt for a tire intended for heavy industrialvehicles selected from among vans, “heavy vehicles”—i.e. subway trains,buses, road transport machinery (lorries, tractors, trailers), off-roadvehicles—agricultural machinery or construction machinery, aircraft andother transport or handling vehicles.

The cable of the invention could however be used, according to otherpossible embodiments of the invention, to reinforce other parts oftires, in particular carcass reinforcements of tires for industrialvehicles such as heavy vehicles.

The invention furthermore relates to these articles or semi-finishedproducts made of rubber themselves when they are reinforced by a cableaccording to the invention, in particular tires intended for industrialvehicles such as heavy vehicles.

The invention and its advantages will be readily understood in the lightof the description and examples of embodiment which follow, and FIGS. 1to 3 relating to these examples, which show, respectively:

-   -   in cross-section, a cable of construction 1+6 according to the        invention, usable in a crown reinforcement for a heavy-vehicle        tire according to the invention (FIG. 1);    -   in cross-section, a cable of construction 2+7 usable in a        conventional crown reinforcement for a heavy-vehicle tire (FIG.        2);    -   in radial section, a heavy-vehicle tire having a radial carcass        reinforcement, whether or not in accordance with the invention        in this general representation (FIG. 3).

I. MEASUREMENTS AND TESTS I-1. Dynamometric Measurements

As regards the metal wires and cables, the measurements of breaking loadFm (maximum load in N), tensile strength Rm (in MPa) and elongation atbreak At (total elongation in %) are carried out under tension inaccordance with Standard ISO 6892 of 1984.

As regards the rubber compositions, the modulus measurements are carriedout under tension, unless indicated otherwise in accordance withStandard ASTM D 412 of 1998 (test piece “C”): the “true” secant modulus(that is to say reduced to the real section of the test piece) at 10%elongation, referred to as E10 and expressed in MPa, is measured in asecond elongation (that is to say after an accommodation cycle) (normalconditions of temperature and relative humidity in accordance withStandard ASTM D 1349 of 1999).

I-2. Air Permeability Test

The air permeability test is a simple way of indirectly measuring theamount of penetration of the cable by a rubber composition. It isperformed on cables extracted directly, by decortication, from thevulcanized rubber plies which they reinforce, and which therefore havebeen penetrated by the cured rubber.

The test is carried out on a given length of cable (for example 2 cm) asfollows: air is sent to the entry of the cable, at a given pressure (forexample 1 bar), and the volume of air at the exit is measured, using aflow meter; during the measurement, the sample of cable is locked in aseal such that only the quantity of air passing through the cable fromone end to the other, along its longitudinal axis, is taken into accountby the measurement. The flow rate measured is all the lower, the higherthe amount of penetration of the cable by the rubber.

II. DETAILED DESCRIPTION OF THE INVENTION

In the present description, unless expressly indicated otherwise, allthe percentages (%) indicated are mass percentages.

II-1. Cable of the Invention

The compact metal cable having two layers (C1, C2) according to theinvention, of construction 1+N, comprises a core or inner layer C1comprising a single core wire of diameter d₁, and a saturated outerlayer C2 of N wires of diameter d₂ wound together in a helix at a pitchp₂ around the layer C1, said layered cable being characterized:

-   -   in that it has the following characteristics (d₁, d₂, p₂ in mm):        -   0.15<d₁<0.50;        -   0.15<d₂<0.50;        -   8<p₂<25;    -   and in that the core wire is surrounded by a sheath of diene        rubber which fills, at least in part, the gaps between the core        wire and the wires of the layer C2.

In other words, the cable of the invention is rubberized internally(i.e. filled at least in part with rubber or “rubberized in situ”): itscore wire and its layer C2 are separated radially by a minimal thickness(or sheath) of rubber (diene elastomer composition), said sheathingrubber furthermore filling, in its entirety or in part, the gaps betweencore wire and wires of the layer C2.

Unless there is possible later coating with rubber or other polymer, thecable of the invention is therefore, as such, devoid of rubber or anyother polymer sheath on its periphery (i.e. around the N wiresconstituting its outer layer C2), as shown for example in the appendedFIG. 1.

Furthermore, a “compact” cable is to be understood here, in a mannerknown to the person skilled in the art, to be a cable the compactness ofwhich is such that this cable cannot be penetrated from the outside by apolymer material, particularly rubber, even in the uncured state.

The wires of layers C1 and C2 may have a diameter which is identical ordifferent from one layer to the other. Preferably wires of the samediameter from one layer to the other (i.e. d₁=d₂) are used, as shown,for example, in the appended FIG. 1. The wire of the layer C1 ispreferably made of steel, more preferably of carbon steel.Independently, the wires of the layer C2 are themselves made of steel,preferably of carbon steel.

According to a preferred embodiment, the layer C2 comprises from 5 to 10wires, in other words the cable of the invention is selected from thegroup consisting of cables of constructions 1+5, 1+6, 1+7, 1+8, 1+9 and1+10; particularly selected from among these cables are those formed ofwires having substantially the same diameter from one layer to the other(namely d₁=d₂).

According to a more preferred embodiment of the invention, the selectedcable has the construction 1+6 or 1+7, more particularly 1+6.

FIG. 1 shows, in a section perpendicular to the axis of the cable(assumed to be rectilinear and at rest), an example of a preferred 1+6cable (cable denoted C-I in the following examples), whereas FIG. 2recalls the section through a conventional 2+7 cable (cable denoted C-IIin the following examples).

The cable according to the invention comprises firstly an inner layer(or core) C1 formed of the core wire 10 covered, preferably over itsentire periphery, with a minimal thickness of sheathing rubber 11,preferably of between 0.01 and 0.10 mm, more preferably still within arange from 0.02 to 0.06 mm, which is therefore less, generally very muchless, than the diameter of said core wire.

The rubber sheath 11 of the cable of the invention extends continuouslyaround said core wire 10 which it covers, that is to say that thissheath is continuous in the “orthoradial” direction of the cable(perpendicular to its radius). In other words, taking into account therange of variation of the diameter d₁, the layer C1 formed of the corewire and of the minimal thickness of sheathing rubber which surrounds ithas a preferred diameter of between 0.16 mm and 0.60 mm, more preferablywithin a range from 0.17 to 0.56 mm.

The layer C1 is itself surrounded by and in contact with an outer layerC2 of six wires 12 (of the same diameter as the core wire 10) which arewound together in a helix at a pitch p₂ around the layer C1, andtherefore of a thickness substantially equal to the diameter d₂ of saidwires 12. It can be seen that the wires 10 and 12 are thus arranged intwo adjacent, concentric, tubular layers (layers C1 and C2), giving thecable its cylindrical contour E.

For comparison, in the cable C-II according to the prior art, the innerlayer C1 is formed of two wires 20 wound together in a helix at a pitchp₁, which inner layer is itself surrounded by and in contact with anouter layer C2 of seven wires 21 wound together in a helix at a pitch p₂around the layer C1, and therefore of a thickness substantially equal tothe diameter d₂ of said wires. The wires 20 and 21 are thus alsoarranged in two adjacent, concentric, tubular layers (layers C1 and C2),giving the cable its cylindrical contour E.

The rubber sheath 11 covers the core wire 10 of the cable of theinvention, but also fills, at least in part, the gaps between the corewire 10 and the wires 12 of the layer C2.

According to one particularly preferred embodiment, these gaps aretotally filled by the sheathing rubber 11, as shown in FIG. 1, saidsheathing rubber 11 thus covering practically at least half the radiallyinner circumference of the wires 12 of the layer C2.

According to a preferred embodiment of the invention, the followingcharacteristics are satisfied (d₁, d₂ in mm):

-   -   0.15<d₁<0.50;    -   0.25<d₂<0.40;    -   0.6<(d₁/d₂)<1.25.

According to a more preferred embodiment, the following characteristicsare satisfied (d₁, d₂ in mm):

-   -   0.20<d₁<0.48;    -   0.25<d₂<0.40;    -   0.8<(d₁/d₂)<1.2.

The layer C1 thus has, in this latter case, a preferred diameter ofbetween 0.21 mm and 58 mm (more preferably within a range from 0.22 to0.54 mm).

For an optimised compromise between strength, feasibility, rigidity andendurance in compression of the cable, it is preferred that thediameters of all the wires of layers C1 and C2, whether or not thesewires are of identical diameters, be within a range from about 0.26 to0.36 mm, the layer C1 therefore having in this case a preferred diameterwithin a range from about 0.27 to 0.46 mm (more preferably from 0.28 to0.42 mm).

The pitch p₂ is selected more preferably between 10 and 20 mm, inparticular when d₁=d₂, more preferably still within a range from 14 to18 mm.

It will be recalled here that in known manner the pitch “p” representsthe length, measured parallel to the axis of the cable, at the end ofwhich a wire having this pitch makes a complete turn around said axis ofthe cable.

“Metal cable” is understood by definition to mean a cable formed ofwires made majoritarily (that is to say to more than 50% of these wires)or fully (for 100% of the wires) of a metallic material. The inventionis preferably carried out with a steel cable, more preferably one madeof perlitic (or ferrito-perlitic) carbon steel hereinafter referred toas “carbon steel”, or alternatively of stainless steel (by definition,steel comprising at least 11% chromium and at least 50% iron). However,it is of course possible to use other steels or other alloys.

When a carbon steel is used, its carbon content is preferably of between0.4% and 1.2%, in particular between 0.5% and 1.1%. It is morepreferably of between 0.6% and 1.0% (% by weight of steel), such acontent representing a good compromise between the mechanical propertiesrequired for the composite and the feasibility of the wires.

The metal or steel used, be it in particular a carbon steel or astainless steel, may itself be coated with a metallic layer whichimproves for example the processing properties of the metal cable and/orits constituent elements, or the use properties of the cable and/or ofthe tire themselves, such as the properties of adhesion, corrosionresistance or alternatively ageing resistance.

According to a preferred embodiment, the steel used is covered with alayer of brass (Zn—Cu alloy) or of zinc; it will be recalled that duringthe process of manufacturing the wires, the brass or zinc coatingfacilitates the drawing of the wire, as well as the sticking of the wireto the rubber. However, the wires could be covered with a fine metallayer other than brass or zinc, having for example the function ofimproving the corrosion resistance of these wires and/or the adhesionthereof to the rubber, for example a fine layer of Co, Ni, Al, or of analloy of two or more of the compounds Cu, Zn, Al, Ni, Co, Sn.

The cables of the invention are preferably made of carbon steel and havea tensile strength (Rm) preferably greater than 2500 MPa, morepreferably greater than 3000 MPa.

The total elongation at break (At) of the cable, the total of itsstructural, elastic and plastic elongations (At=As+Ae+Ap), is preferablygreater than 2.5%, more preferably greater than 3.0%.

The person skilled in the art will know how to manufacture steel wireswhich result in such characteristics, by adjusting in particular thecomposition of the steel and the final work-hardening ratios of thesewires, according to his own particular needs, using for examplemicro-alloyed carbon steels containing specific alloying elements suchas Cr, Ni, Co, V, or various other known elements (see for exampleResearch Disclosure 34984—“Micro-alloyed steel cord constructions fortires”—May 1993; Research Disclosure 34054—“High tensile strength steelcord constructions for tires”—August 1992).

The cable of the invention therefore comprises around its core wire arubber matrix or composition (called “sheathing rubber”) comprising atleast one diene elastomer.

The diene elastomer is preferably selected from the group consisting ofpolybutadienes (BR), natural rubber (NR), synthetic polyisoprenes (IR),the various butadiene copolymers, the various isoprene copolymers, andmixtures of these elastomers. Such copolymers are more preferablyselected from the group consisting of butadiene/styrene copolymers(SBR), whether the latter be prepared by emulsion polymerisation (ESBR)or by solution polymerisation (SSBR), isoprene/butadiene copolymers(BIR), isoprene/styrene copolymers (SIR) and isoprene/butadiene/styrenecopolymers (SBIR).

A preferred embodiment consists of using an “isoprene” elastomer, thatis to say an isoprene homopolymer or copolymer, in other words a dieneelastomer selected from the group consisting of natural rubber (NR),synthetic polyisoprenes (IR), the various isoprene copolymers andmixtures of these elastomers.

The isoprene elastomer is preferably natural rubber or a syntheticpolyisoprene of the cis-1,4 type. Of these synthetic polyisoprenes,preferably polyisoprenes having a content (mole %) of cis-1,4 bondsgreater than 90%, more preferably still greater than 98%, are used.According to other preferred embodiments, the diene elastomer may beconstituted, in its entirety or in part, of another diene elastomer suchas, for example, an SBR elastomer used in a blend or not with anotherelastomer, for example of the BR type.

The sheathing rubber may contain a single or several diene elastomer(s),the latter possibly being used in association with any type of syntheticelastomer other than a diene elastomer, or even with polymers other thanelastomers.

The sheathing rubber is of the cross-linkable or cross-linked type, thatis to say that it by definition comprises a cross-linking systemsuitable to permit cross-linking of the composition upon the curingthereof (i.e. its hardening). Preferably, the cross-linking system forthe rubber sheath is what is called a vulcanization system, that is tosay one based on sulfur (or a sulfur donor) and a primary vulcanizationaccelerator. Various known secondary accelerators or vulcanizationactivators may be added to this base vulcanization system. The sulfur isused in a preferred amount of between 0.5 and 10 phr, more preferably ofbetween 1 and 8 phr; the primary vulcanization accelerator, for examplea sulfenamide, is used in a preferred amount of between 0.5 and 10 phr,more preferably between 0.5 and 5.0 phr.

The sheathing rubber may also comprise, in addition to saidcross-linking system, all or some of the additives usually used inrubber matrices intended for the manufacture of tires, such as forexample reinforcing fillers such as carbon black or inorganic fillerssuch as silica, coupling agents, anti-ageing agents, antioxidants,plasticising agents or extender oils, whether the latter be of aromaticor non-aromatic nature (in particular oils which are only very slightlyaromatic or non-aromatic, for example of the naphthenic or paraffinictype, of high or preferably of low viscosity, MES or TDAE oils,plasticising resins of high Tg greater than 30° C., agents whichfacilitate the processing (processability) of the compositions in theuncured state, tackifying resins, anti-reversion agents, methyleneacceptors and donors such as for example HMT (hexamethylenetetramine) orH3M (hexamethoxymethylmelamine), reinforcing resins (such as resorcinolor bismaleimide), known adhesion-promoting systems of the metal salttype for example, in particular cobalt or nickel salts.

The amount of reinforcing filler, for example carbon black or areinforcing inorganic filler such as silica, is preferably greater than50 phr, for example of between 60 and 140 phr. It is more preferablygreater than 70 phr, for example between 70 and 120 phr.

Suitable carbon blacks are all carbon blacks, particularly blacks of thetype HAF, ISAF and SAF, conventionally used in tires (what are calledtire-grade blacks). Of the latter, mention will more particularly bemade of the carbon blacks of grade (ASTM) 300, 600 or 700 (for exampleN326, N330, N347, N375, N683, N772). Suitable reinforcing inorganicfillers are in particular mineral fillers of silica type (SiO₂), inparticular precipitated or fumed silicas having a BET surface area ofless than 450 m²/g, preferably from 30 to 400 m²/g.

The person skilled in the art will be able, in the light of the presentdescription, to adjust the formulation of the sheathing rubber in orderto achieve the desired levels of properties (in particular elasticitymodulus), and to adapt the formulation to the specific intendedapplication.

Preferably, the formulation of the sheathing rubber is selected to beidentical to the formulation of the rubber matrix which the cables ofthe invention are intended to reinforce. Thus, there is no problem ofcompatibility between the respective materials of the sheathing rubberand of said rubber matrix which the cable of the invention is intendedto reinforce.

Preferably, the sheathing rubber, in the cross-linked state, has asecant tensile modulus E10 (at 10% elongation) of between 5 and 25 MPa,more preferably between 5 and 20 MPa, in particular within a range from7 to 15 MPa.

The cable according to the invention may be manufactured according tovarious techniques known to the person skilled in the art, for example:

-   -   (i) first of all by sheathing, via an extrusion head, the core        wire (10) with the sheathing rubber (11) in the uncured state,        followed by    -   (ii) a final cabling operation, preferably in line with the        previous one, of the N wires (12) of the layer C2 around the        layer C1 thus rubberized, during which operation the N wires        will come to bear on and become embedded in the uncured        sheathing rubber, the latter then naturally tending to fill, at        least in part, preferably totally, the gaps left empty between        the core wire (10) and the wires (12) during the putting in        place of the layer C2 under the pressure exerted by said wires        (12) on the sheathing rubber.

The invention relates of course to the cable previously described, bothin the uncured state (its sheathing rubber then being non-vulcanized)and in the cured state (its sheathing rubber then being vulcanized).

II-2. Tire of the Invention

The cable of the invention is advantageously usable in crownreinforcements for all types of tires, in particular for tires forindustrial vehicles such as heavy vehicles.

By way of example, FIG. 3 shows diagrammatically a radial sectionthrough a tire having a metallic crown reinforcement which may or maynot be in accordance with the invention, in this general representation.This tire 1 comprises a crown 2 reinforced by a crown reinforcement orbelt 6, two sidewalls 3 and two beads 4, each of these beads 4 beingreinforced by a bead wire 5. The crown 2 is surmounted by a tread notshown in this diagrammatic figure. A carcass reinforcement 7 is woundaround the two bead wires 5 within each bead 4, the upturn 8 of thisreinforcement 7 being for example arranged towards the outside of thetire 1, which is shown here mounted on its rim 9. The carcassreinforcement 7 in a manner known per se is formed of at least one plyreinforced by what are called “radial” cables, that is to say that thesecables are arranged practically parallel to each other and extend fromone bead to the other so as to form an angle of between 80° and 90° withthe median circumferential plane (plane perpendicular to the axis ofrotation of the tire which is located half-way between the two beads 4and passes through the centre of the crown reinforcement 6).

The tire according to the invention is characterized in that its belt 6comprises at least, as reinforcement of at least one of the belt plies,a two-layer metal cable according to the invention. In this belt 6,which is illustrated very simply in FIG. 3, it will be understood thatthe cables of the invention may for example reinforce all or part ofwhat are called the working belt plies, or of what are called thetriangulation plies (or half-plies) and/or of what are called theprotective plies, when such triangulation or protective plies are usedin the belt 6. In addition to the working plies, the triangulationand/or protective plies, the belt 6 of the tire of the invention may ofcourse comprise other plies, for example one or more what are calledhooping plies.

Of course, this tire 1 furthermore comprises in known manner an internalrubber or elastomer layer (commonly referred to as “internal rubber”)which defines the radially inner face of the tire and which is intendedto protect the carcass ply from the diffusion of air coming from theinterior of the tire. Advantageously, in particular in the case of atire for a heavy vehicle, it may furthermore comprise an intermediateelastomer reinforcement layer which is located between the carcass plyand the inner layer, intended to reinforce the inner layer and,consequently, the carcass ply, and also intended partially to delocalisethe forces to which the carcass reinforcement is subjected.

In this belt ply, the density of the cables according to the inventionis preferably between 15 and 80 cables per dm (decimetre) of belt ply,more preferably between 35 and 65 cables per dm of ply, the distancebetween two adjacent cables, from axis to axis, preferably being betweenabout 1.2 and 6.5 mm, more preferably between about 1.5 and 3.0 mm.

The cables according to the invention are preferably arranged such thatthe width (L) of the rubber bridge, between two adjacent cables, isbetween 0.5 and 2.0 mm. This width L in known manner represents thedifference between the calendering pitch (laying pitch of the cable inthe rubber fabric) and the diameter of the cable. Below the minimumvalue indicated, the rubber bridge, which is too narrow, risksmechanically degrading during working of the ply, in particular duringthe deformation which it experiences in its own plane by extension orshearing. Beyond the maximum indicated, there are risks of penetrationof objects occurring, by perforation, between the cables. Morepreferably, for these same reasons, the width L is selected to bebetween 0.8 and 1.6 mm.

Preferably, the rubber composition used for the fabric of the belt plyhas, when vulcanized (i.e. after curing), a secant tensile modulus E10which is between 5 and 25 MPa, more preferably between 5 and 20 MPa, inparticular within a range from 7 to 15 MPa, when this fabric is intendedto form a working ply of the belt. It is within such ranges of modulithat the best compromise of endurance was recorded between the cables ofthe invention on one hand and the fabrics reinforced with these cableson the other hand.

III. EXAMPLES OF EMBODIMENT OF THE INVENTION III-1. Nature andProperties of the Wires Used

In the following tests layered cables of constructions 1+6 and 2+7 suchas depicted in FIGS. 1 and 2, formed of fine carbon steel wires coatedwith brass, are used.

The carbon steel wires are prepared in known manner, starting, forexample, from machine wires (diameter 5 to 6 mm) which are first of allwork-hardened, by rolling and/or drawing, to an intermediate diameterclose to 1 mm.

The steel used for the cable C-I (wires denoted “F-I”) according to theinvention is a carbon steel of the very-high-strength type (referred toas SHT for “Super High Tensile”), the carbon content of which isapproximately 0.92%, comprising approximately 0.2% of chromium, the restbeing formed of iron and the usual unavoidable impurities linked to thesteel manufacturing process.

The one used for the control cable C-II (wires denoted “F-II”) is acarbon steel of the high-strength type (referred to as HT for “HighTensile”), the carbon content of which is approximately 0.82%,comprising approximately 0.5% of manganese (rest formed of iron andimpurities).

The wires of intermediate diameter undergo a degreasing and/or picklingtreatment before their subsequent transformation. After depositing abrass coating on these intermediate wires, what is called “final”work-hardening is effected on each wire (i.e. after the final heattreatment of patenting), by cold-drawing in a wet medium with a drawinglubricant which is for example in the form of an aqueous emulsion ordispersion.

The steel wires thus drawn have the following diameters and mechanicalproperties:

TABLE 1 Wires φ (mm) Fm (N) Rm (MPa) F-I 0.350 263 2765 F-II 0.260 1803380

The brass coating surrounding the wires is of very low thickness,significantly less than one micrometre, for example of the order of 0.15to 0.30 μm, which is negligible compared with the diameter of the steelwires. Of course, the composition of the steel of the wire in terms ofits different elements (for example C, Cr, Mn) is the same as that ofthe steel of the starting wire.

III-2. Production of the Cables

These wires are then assembled in the form of different cylindricallayered cables, referenced C-I and C-II, the construction and themechanical properties of which are given in Table 2.

TABLE 2 p₁ p₂ Fm Rm At Cable Construction (mm) (mm) (daN) (MPa) (%) C-I(1 + 6) 0.26 SHT ∞ 15.4 125 3315 2.7 C-II (2 + 7) 0.35 HT 7.7 15.4 2202560

The 1+6 cable, as depicted in FIG. 1, is therefore formed of 7 wires F-Iin total. It comprises a core C1 comprising the core wire sheathed withrubber (deposited via an extrusion head, before the wires of the layerC2 are put in place), this layer C1 being in contact with a cylindricalouter layer of 6 wires which themselves are wound together in a helix (Sdirection) around the core, at the pitch p₂. The rubber sheath herefills the entirety or virtually the entirety of the gaps between thecore wire and the wires of the layer C2. It can clearly be seen thatthis cable of the invention is of the compact type, that is to say thatits layer C2 cannot be penetrated from the outside by the rubber, evenin the uncured state (not cross-linked).

The 2+7 control cable, as depicted in FIG. 2, is formed of 9 wires F-IIin total. It comprises an inner layer C1 of 2 wires wound together in ahelix (S direction) at the pitch p₁, this layer C1 being in contact witha cylindrical outer layer of 7 wires which themselves are wound togetherin a helix (S direction) around the core, at the pitch p₂. This cable,which is highly aerated and of low compactness compared with the cableC-I of the invention, is devoid of rubber.

The elastomeric composition (based on natural rubber and carbon black)constituting the sheathing rubber of the cable of the invention has thesame formulation as that of the rubber belt ply which the cable C-I isintended to reinforce in the following test.

III-3. Endurance in Tire

The layered cables C-I and C-II are then incorporated by calendering incomposite fabrics formed of a known composition based on natural rubberand carbon black as reinforcing filler, used conventionally for themanufacture of belt plies of radial heavy-vehicle tires. Thiscomposition essentially comprises, in addition to the elastomer and thereinforcing filler (carbon black), an antioxidant, stearic acid, anextender oil, cobalt naphthenate as adhesion promoter, and finally avulcanization system (sulfur, accelerator, ZnO).

The composite fabrics reinforced by these cables comprise a rubbermatrix formed of two fine layers of rubber which are superposed oneither side of the cables and which have a thickness of 0.5 mm (cableC-I) or 0.8 mm (cable C-II) respectively. The calendering pitch (layingpitch of the cables in the rubber fabric) is 1.3 mm (cable C-I) or 2.8mm (cable C-II).

Two series of running tests for heavy-vehicle tires (designated P-I andP-II) of dimensions 11R22.5 XZE are then carried out, with tiresintended for running, and others for decortication on a new tire, ineach series.

The tires P-I reinforced by the cables C-I of the invention are thetires according to the invention. The tires P-II reinforced by thecables C-H constitute the control tires of the prior art; owing to theirrecognised performance they constitute a control of choice for thistest.

The tires P-I and P-II are therefore identical with the exception of thetwo-layer cables which reinforce their belts 6.

Their crown reinforcements or belts 6, in particular, are in a mannerknown per se formed of two triangulation half-plies reinforced withmetal cables inclined at 65 degrees, surmounted by two superposedcrossed “working plies”. These working plies are reinforced with theabove metal cables (C-I and C-II respectively) arranged substantially inparallel relative to one another and inclined by 26 degrees (radiallyinner ply) and 18 degrees (radially outer ply). The two working pliesare furthermore covered by a protective ply reinforced with conventionalelastic metal cables (high elongation) inclined by 18 degrees. All theangles of inclination indicated are measured relative to the mediancircumferential plane.

These tires are made to undergo a stringent running test, under overloadconditions, intended to test their resistance to the phenomenon known as“cleavage” (separation of the ends of the belt plies), by subjecting thetires (on an automatic rolling machine) to sequences of very strongcornering and strong compression of their crown blocks in the shoulderzone. The test is carried out until forced destruction of the tiresoccurs.

It will then be noted that the tires P-I reinforced by the cables of theinvention, under the very severe running conditions which are imposedthereon, exhibit distinctly improved endurance: the average distancetraveled is increased by 35% relative to the control tires, whichfurthermore already exhibit an excellent performance.

The non-fatigued cables C-I and C-II, after extraction from the newtires, were furthermore subjected to the air permeability test describedin section I-1, by measuring the volume of air (in cm³) passing throughthe cables in 1 minute (average of 10 measurements).

Table 3 below shows the results obtained, in terms of average flow rateof air (average of 10 measurements—in relative units base 100 on thecontrol cables) and of number of measurements corresponding to a zeroair flow rate.

TABLE 3 Average flow rate of air Number of measurements Cable (relativeunits) at zero flow rate: C-I 0 100/100 C-II 100  30/100

The cable C-I of the invention is the one which, by far, has the lesserair permeability, since it is virtually zero (average flow rate of airzero or practically zero) and consequently the greater amount ofpenetration by the rubber, taking into account its specific constructionand the rubberizing thereof in situ.

Finally, adhesion tests showed a significantly improved resistance tocorrosion, with gains which may reach 100 to 150% on the cables C-I ofthe invention, compared with the control cables C-II.

In conclusion, the cables of the invention make it possible to improvesignificantly the fatigue strength and/or corrosion resistance undercompression, in particular the resistance to the phenomena of cleavagein the belts of heavy-vehicle tires.

Of course, the invention is not limited to the examples of embodimentdescribed above.

Thus, for example, the core of the cable of the invention might beformed of a wire of non-circular section, for example one which isplastically deformed, in particular a wire of substantially oval orpolygonal section, for example triangular, square or alternativelyrectangular.

For reasons of industrial feasibility, cost and overall performance, itis however preferred to implement the invention with a singleconventional linear core wire, that is to say one of circular section.

The core C0 might also be formed of a preformed wire, whether or not ofcircular section, for example an undulating or corkscrewed wire, or onetwisted into the shape of a helix or a zigzag. In such cases, it shouldof course be understood that the diameter d₁ of the core represents thediameter of the imaginary cylinder of revolution which surrounds thecore wire (diameter of bulk), and not the diameter (or any othertransverse size, if its section is not circular) of the core wireitself.

The invention also relates to any multi-strand steel cable(“multi-strand rope”), the structure of which incorporates, at least, asthe elementary strand, a layered cable according to the invention.

1. A compact metal cable having two layers (C1, C2) of construction 1+N,rubberized in situ, comprising a core or inner layer (C1) comprising asingle core wire of diameter d₁, and a saturated outer layer (C2) of Nwires of diameter d₂ wound together in a helix at a pitch p₂ around thelayer C1, said layered cable being characterized: in that it has thefollowing characteristics (d₁, d₂, p₂ in mm): 0.15<d₁<0.50;0.15<d₂<0.50; 8<p₂<25; and in that the core wire is surrounded by asheath of diene rubber which fills, at least in part, the gaps betweenthe core wire and the wires of the layer C2.
 2. The cable according toclaim 1, wherein the diene elastomer of the rubber sheath is selectedfrom the group consisting of polybutadienes, natural rubber, syntheticpolyisoprenes, butadiene copolymers, isoprene copolymers and mixtures ofthese elastomers.
 3. The cable according to claim 2, wherein the dieneelastomer is selected from the group consisting of natural rubber,synthetic polyisoprenes, isoprene copolymers and mixtures of theseelastomers.
 4. The cable according to claim 3, wherein the dieneelastomer is natural rubber.
 5. The cable according to claim 1, wherein,wherein said rubber sheath comprises carbon black as reinforcing filler.6. The cable according to claim 1, wherein, the rubber sheath has, inthe cross-linked state, a secant tensile modulus, at 10% extension, E10,which is between 5 and 25 MPa.
 7. The cable according to claim 6,wherein the modulus E10 is between 5 and 20 MPa.
 8. The cable accordingto claim 7, E10 is within a range from 7 to 15 MPa.
 9. The cableaccording to claim 1, wherein said cable has the followingcharacteristics (d₁, d₂ in mm): 0.15<d₁<0.50; 0.25<d₂<0.40;0.6<(d₁/d₂)<1.25.
 10. The cable according to claim 9, has the followingcharacteristics (d₁, d₂ in mm): 0.20<d₁<0.48; 0.25<d₂<0.40;0.8<(d₁/d₂)<1.2.
 11. The cable according to claim 1, wherein, p₂ isbetween 10 and 20 mm.
 12. The cable according to claim 11, wherein p₂ iswithin a range from 14 to 18 mm.
 13. The cable according to claim 1,wherein, the layer C2 comprises five to ten wires.
 14. The cableaccording to claim 13, wherein the layer C2 comprises six or sevenwires.
 15. The cable according to claim 14, wherein the layer C2comprises six wires.
 16. The cable according to claim 1, wherein, therubber sheath surrounding the core wire has a minimal thickness ofbetween 0.01 mm and 0.10 mm.
 17. The cable according to claim 16,wherein the rubber sheath surrounding the core wire has a minimalthickness within a range from 0.02 mm to 0.06 mm.
 18. The cableaccording to claim 1, wherein, the wire of the layer C1 is of steel. 19.The cable according to claim 1, wherein, the wire of the layer C2 is ofsteel.
 20. The cable according to claim 18, wherein, the steel being acarbon steel.
 21. The cable according to claim 20, wherein the carboncontent of the steel is between 0.4 and 1.2%.
 22. The cable according toclaim 21, wherein the carbon content of the steel is between 0.6 and1.0%.
 23. The cable according to claim 1, wherein, in which d₁=d₂. 24.(canceled)
 25. (canceled)
 26. A tire reinforced with a cable accordingto claim
 1. 27. A tire reinforced with a cable, comprising a carcassreinforcement which is anchored in two beads and which is radiallysurmounted by a belt which in turn is surmounted by a tread which isjoined to said beads by two sidewalls, wherein said belt comprises ametal cable according to claim 1.